Model Curriculum Operator-Reaper, Thresher and Crop Residue Machinery

SECTOR: AGRICULTURE & ALLIED SUB-SECTOR: AGRICULTURE CROP PRODUCTION OCCUPATION: FARM MACHINERY, EQUIPMENT OPERATION AND MAINTENANCE REF ID: AGR/Q1105, V1.0 NSQF LEVEL: 4

Operator-Reaper, Thresher and Crop Residue Machinery

Operator-Reaper, Thresher and Crop Residue Machinery

TABLE OF CONTENTS

1. Curriculum 04 2. Trainer Prerequisites 10 3. Annexure: Assessment Criteria 11

Operator-Reaper, Thresher and Crop Residue Machinery Operator-Reaper, Thresher and Crop Residue Machinery CURRICULUM / SYLLABUS

This program is aimed at training candidates for the job of a “Operator-Reaper, Thresher and Crop Residue Machinery”, in the “Agriculture & Allied” Sector/Industry and aims at building the following key competencies amongst the learner

Program Name Operator-Reaper, Thresher and Crop Residue Machinery

Qualification Pack Name AGR/Q1005, v1.0 & Reference ID.

Version No. 1.0 Version Update Date

Pre-requisites to Training Class 8, preferably

Training Outcomes After completing this programme, participants will be able to:

 Operate reaper: handling of reaper during different operation on various crops.  Operate thresher: handling of thresher during different operation on various crops  Carry out field residue management: select appropriate equipment, operate the equipment  Carry out minor repair and periodical maintenance of agriculture machineries: periodic checking, tightening, greasing, cross-checking for any leakages etc  Practice health and safety at the work place: Well versed with health and safety measures in terms of personal as well as others’ safety.

Operator-Reaper, Thresher and Crop Residue Machinery This course encompasses 4 out of 4 Compulsory NOS (National Occupational Standards), 1 out of 1 Optional NOS of “Operator-Reaper, Thresher and Crop Residue Machinery” Qualification Pack issued by “Agriculture Skill Council of India”.

COMPULSORY NOS:

Sr. Module Key learning outcomes Equipment Required No. 1 Introduction  Understand general discipline in the Laptop, white board, class room and workshop (Do’s & marker, projector and Theory Duration Don’ts) video films and (hh:mm)  Study the scope and importance of Presentations 02:00 farm mechanization industry in India  Familiarize with different farm Practical Duration machineries’ manufacturers and their (hh:mm) brands/models 00:00  Understand the role of a Operator- Reaper, Thresher and Crop residue Corresponding NOS Machinery and the progression Code pathways for the same Bridge Module

2 Carry out operation of  State the importance of reaper Laptop, white board, reaper  Enlist the types of reaper marker, projector  Select vertical conveyor reaper or vertical conveyor Theory Duration self propelled reaper based on crop reaper or self propelled (hh:mm) variety, maturity of crop, crop reaper 18:00 moisture, crop condition and crop density Practical Duration  Identify steps of fitting the reaper (hh:mm) with the tractor/ engine 40:00  Mount the reaper in the tractor  State the importance of alignment of Corresponding NOS reaper Code  Check the alignment of the reaper AGR/N1115 with the prime mover

 Carry out tightening of nuts and bolts with proper tools  Apply lubrication on parts of reaper as per operator’s manual  Check the level of oil/water in IC engine or tractor  Set the adjustment of the reaper as per the operator’s manual  Prepare agricultural land as per requirement of farm mechanization practices  Identify the steps for operating tractor operated /engine operated reaper for harvesting crops  Identify precautions to be taken during operation of reaper in field  Operate the reaper in field  Carry out recording and measurement of operating parameters during operations of the

Operator-Reaper, Thresher and Crop Residue Machinery Sr. Module Key learning outcomes Equipment Required No. reaper  Record the impact on crop variety  Identify operating troubles during operation such as blocked discharge, cutting knife and conveyor belts stopped, loss of power  Make corrective adjustments in accordance with the operator’s manual  Identify need for maintenance and repair of the reaper  Make corrective adjustments in accordance with the operator’s manual  Inspect and clean the guards  Inspect the conveyor belt for damages and replace if necessary  Check the tension of v-belt over the roller pulley  Inspect the cutter bar, knife, star wheels, pressure springs and lugs for damage and take corrective actions  Lubricate all moving parts  Repaint surface where paint has worn off  Familiarize with the road signal and communication signs used for tractors and agricultural machinery

3 Carry out operation of  Select the right thresher based on the tractor/power tiller Thresher type, capacity and suitability to crops harvesting/reaping  Check the direction of wind and install equipments Theory Duration thresher along the direction of the threshing/shelling (hh:mm) wind equipments 20:00  Ensure that the thresher is at level by trolleys for material fixing pegs around the wheels handling Practical Duration  Mount the prime mover on the frame repairing tools (hh:mm) and check alignment service tools 40:00  Check belt technician and accordingly correct as per the operator’s manual Corresponding NOS  Carry out adjustments for speed of Code threshing cylinder, cylinder concave AGR / N1116 clearance, speed of blower, air flow, sieve slope and stroke length and speed of crank according to operator’s manual  Ensure all nuts and bolts are tightened  Check the level, alignment of thresher and ensure appropriate belt tension  Check the proper size of sieve and conclave  Check the direction of rotation of cylinder

Operator-Reaper, Thresher and Crop Residue Machinery Sr. Module Key learning outcomes Equipment Required No.  Ensure lubrication of parts as per operator’s manual  Check the level of oil/water in I/c engine or tractor  Start the prime mover and thresher  Measure the speed of the thresher using a prime mover and ensure the desired speed is maintained  Feed crop slowly and uniformly and collect the clean grain after 1 hour of operation  Measure threshing efficiency and change cylinder speed to ensure maximum efficiency  Ensure safety precautions as per operator’s manual during operation of thresher  Carry out basic repair and maintenance as per operator’s manual  Clean the thresher of grain, chaff, etc. during idle period  Carry out regular lubrication of moving parts to reduce wear and tear  Inspect and tighten all nuts and bolts

4 Carry out field residue  Select appropriate farm machinery to straw chopper, straw management facilitate the application of residues baler, seeder, chaff such as straw chopper, straw baler, cutter, straw reaper, etc happy seeder, chaff cutter, etc . Theory Duration  Check for proper functioning of the (hh:mm) machinery by performing pre start up 20:00 checks  Carry out rectifying action if necessary Practical Duration  Stack the straw neatly for pickup (hh:mm)  Choose the mode of transport for 40:00 transportation of straw to the storage facility such as tractors, trailers Corresponding NOS  Check functioning of chain conveyor, Code pressing rollers, and upper and lower AGR/N1117 feed rollers

 Identify and familiarize self with different sub assemblies and components, materials, construction of straw choppers  Operate the machine as per standard operating instructions given  Identify faults and take corrective action  Pick up straw/hay from the ground using baler teeth  Ensure that once the baler chamber is full with hay/straw, the hay wraps and

Operator-Reaper, Thresher and Crop Residue Machinery Sr. Module Key learning outcomes Equipment Required No. forms a cylinder  Ensure that protective coating has been attached to the cylindrical bundle of hay so that it does not come apart during movement  Transport the able of straw/hay to the designated area of storage  Select the appropriate hard or power operated chaff cutters  Check for adjustments of chaff cutter such as feeding chute and mechanism, feeding rollers, cutting gap, length of cut, etc.  Identify common faults and take rectifying action  Record the quality of output  Identify the need for repair and maintenance like replacement of gears, sharpening of cutting blade, etc.  Develop inventory for amount of residues generated in different crops  Identify the major uses of crop residues  Quantify proportion of residue of the crops based on cropping systems, soil, and climate

5 Maintain Health & Safety  Undertake basic safety checks before Personal protective at the work place operation of all machinery and equipment like: Helmet vehicles and report all potential / head gear, Cotton / Theory Duration woolen safety gloves, hazards to the supervisor (hh:mm) Safety boots, 10:00  Enlist the precautionary measures Safety Harness; during field operation of farm First Aid Kit: Practical Duration machinery Bandages, (hh:mm)  Explain the importance and use of Adhesive bandages, 10:00 protective clothing or equipment Betadine Solution /  Handle the protective clothing or ointment, Pain relief Corresponding NOS equipment during use of equipment spray / ointment, Code  Identify appropriate emergency Antiseptic liquid; AGR/N9903 procedures Phone directory,  Report timely to appropriate person Search lights, fire  Employ general safety and first aid extinguisher practice  Familiarize with dangerous machines regulation act

Total Duration: Unique equipment required: vertical conveyor reaper or self propelled reaper, straw chopper, Theory Duration straw baler, seeder, chaff cutter, straw reaper, Personal protective (hh:mm) equipment like: Helmet / head gear, Cotton / woolen safety gloves, 70:00 Safety boots, Safety Harness; First Aid Kit: Bandages, Adhesive bandages, Betadine Solution / ointment, Pain relief spray / ointment,

Operator-Reaper, Thresher and Crop Residue Machinery Sr. Module Key learning outcomes Equipment Required No. Practical Duration Antiseptic liquid; Phone directory, Search lights, fire extinguisher, (hh:mm) tractor/power tiller, harvesting/reaping equipments, 130:00 threshing/shelling equipments, trolleys for material handling, repairing tools, service tools

OPTIONS (Optional to choose any or all or none)

OPTION 1: Carry out operation of crop residue management machinery

Sr. Equipment Module Key Learning Outcomes No. Required 1 Carry out operation of  Select and use appropriate machinery for Computer, Audio- crop residue various works visual aids, management  Select the cleaning machine as per Projector, Post machinery requirement harvest machinery,  Explain types of cleaner/ grader like air cleaner/ grader like Theory Duration screen cleaners, rotary cleaners, etc. air screen cleaners, (hh:mm) based on suitability to farm produce rotary cleaners, 10:00  Check for adjustment and alignment of batch dryer, LSU feed rate, sieve slope, air flow rate, dryer, grader, straw Practical Duration frequency of oscillations chopper, straw (hh:mm)  Carry out operation of straw chopper baler, dal mill, rice 10:00  Carry out operation of straw baler mill, flour mill, oil  Maintain record the quality of output of ghani, screw Corresponding NOS the grain expeller, hydraulic Code press, etc  Identify common faults and take rectifying AGR/N1118 action

 State importance of drying  Explain drying method like convection/ conduction drying, vacuum drying and the appropriate dryer like batch dryer, LSU dryer, etc.  Check for adjustments of air temperature, grain flow rate in accordance with operator manual  Select the appropriate type of mill like based on the type of crop for example dal mill, rice mill, four mills, etc.  Carry out operation of milling and oil expelling machinery basis crop type  Maintain record the quality of output  Identify common faults and take rectifying action  Carry out regular maintenance of the machineries and attachments

OPTION 1 : Total Unique Equipment Required: Duration Computer, Audio-visual aids, Projector, Post harvest machinery, cleaner/ grader like air screen cleaners, rotary cleaners, batch dryer, Theory Duration LSU dryer, grader, straw chopper, straw baler, dal mill, rice mill, 10:00 flour mill, oil ghani, screw expeller, hydraulic press

Operator-Reaper, Thresher and Crop Residue Machinery Sr. Equipment Module Key Learning Outcomes No. Required

Practical Duration 10:00

GRAND Total Duration Unique Equipment Required for the QP: Laptop, white board, marker, projector, vertical conveyor reaper or Minimum Duration for self propelled reaper, straw chopper, straw baler, seeder, chaff the QP= 200 hrs cutter, straw reaper, Personal protective equipment like: Helmet / Theory: 70 hrs head gear, Cotton / woolen safety gloves, Safety boots, Safety Practical: 130 hrs Harness; First Aid Kit: Bandages, Adhesive bandages, Betadine Solution / ointment, Pain relief spray / ointment, Antiseptic liquid; Maximum Duration for Phone directory, Search lights, fire extinguisher, tractor/power tiller, the QP= 220 hrs harvesting/reaping equipments, threshing/shelling equipments, Theory: 80 hrs trolleys for material handling, repairing tools, service tools, vertical Practical: 140 hrs conveyor, reaper or self propelled reaper, cleaner/ grader like air screen cleaners, rotary cleaners, dryer, straw chopper, straw baler, repairing tools, Post harvest machinery, cleaner/ grader like air screen cleaners, rotary cleaners, batch dryer, LSU dryer, grader, straw chopper, straw baler, dal mill, rice mill, flour mill, oil ghani, screw expeller, hydraulic press

(This syllabus/ curriculum has been approved by Agriculture Skill Council of India)

Operator-Reaper, Thresher and Crop Residue Machinery Trainer Prerequisites for Job role: “Operator-Reaper, Thresher and Crop Residue Machinery” mapped to Qualification Pack: “AGR/Q1105, v1.0”

Sr. Area Details No. 1 Description Trainer is responsible for educating the trainees –handling of reaper, thresher during different operation on various crops; carry out field residue management and maintenance and minor repair and periodical maintenance of agriculture machineries. 2 Personal Trainer should be Subject Matter Expert. He/ she should have good Attributes communication, leadership, observation and practical oriented skills. 3 Minimum 10+2 with Science Educational Qualifications 4a Domain Certified for Job Role: “Operator-Reaper, Thresher and Crop Residue Certification Machinery” mapped to QP: “AGR/Q1105, v1.0”. Minimum accepted score is 80%. 4b Platform Recommended that the Trainer is certified for the Job Role: “Trainer”, mapped Certification to the Qualification Pack: “MEP/Q0102”. Minimum accepted % as per respective SSC guidelines is 80%. 5 Experience • B Tech in Mechanical / Agriculture engineering • B Sc Agriculture with 1 year of relevant work experience and 2 years of total work experience • Diploma / ITI (Mechanical / Agriculture engineering) with 3 years of relevant work experience • 10+2 with Science and having any Certificate course in Farm Mechanization with 5 years of relevant work experience

Operator-Reaper, Thresher and Crop Residue Machinery Annexure: Assessment Criteria

Job Role Operator-Reaper thresher and crop residue machinery Qualification Pack AGR/Q1105, v1.0 Sector Skill Council Agriculture Skill Council of India

Guidelines for Assessment

1. Criteria for assessment for each Qualification Pack will be created by the Sector Skill Council. Each Performance Criteria (PC) will be assigned marks proportional to its importance in NOS. SSC will also lay down proportion of marks for Theory and Skills Practical for each PC. 2. The assessment for the theory part will be based on knowledge bank of questions created by the SSC. 3. Assessment will be conducted for all compulsory NOS, and where applicable, on the selected elective/option NOS/set of NOS. 4. Individual assessment agencies will create unique question papers for theory part for each candidate at each examination/training center (as per assessment criteria below). 5. Individual assessment agencies will create unique evaluations for skill practical for every student at each examination/training center based on this criterion. 6. To pass the Qualification Pack , every trainee should score a minimum of 70% of aggregate marks to successfully clear the assessment. 7. In case of unsuccessful completion, the trainee may seek reassessment on the Qualification Pack.

Compulsory Marks Allocation Total Marks: 400 Total Out Of Theory Skills Marks Practical Assessment outcomes Assessment criteria for outcomes 1. AGR/N1115 Carry out 100 PC1. select the appropriate type of reaper, operation of reaper vertical conveyor reaper or self propelled reaper based on: · crop variety 5 2 3 · maturity of crop · crop moisture · crop condition · crop density

PC2. fit the reaper with the tractor/ 5 2 3 engine based on the type of reaper

PC3. check the alignment of the reaper 5 2 3 with the prime mover

PC4. ensure all nuts and bolts are 4 1 3 tightened

PC5. ensure lubrication of parts as per 4 1 3 operator’s manual

PC6. check the level of oil/water in IC 5 1 4 engine or tractor

PC7. set the adjustment of the following 5 1 4 in accordance with operator’s manual

Operator-Reaper, Thresher and Crop Residue Machinery · reel · cutter bar · binding and tying mechanism · conveyor tension · bundle size

PC8. ensure field patterns and field 5 2 3 preparations are made prior to operation

PC9. switch on the prime mover, tractor or 5 1 4 engine

PC10. operate the reaper for harvesting 4 1 3 crops

PC11. measure and record parameters 5 1 4 during operations of the reaper PC12. record the impact on crop variety 4 1 3

PC13. identify operating troubles during operation such as blocked discharge, cutting 5 1 4 knife and conveyor belts stopped, loss of power

PC14. make corrective adjustments in 5 2 3 accordance with the operator’s manual

PC15. identify need for minor maintenance 5 2 3 and repair of the reaper PC16. inspect and clean the guards 4 1 3

PC17. inspect the conveyor belt for 5 1 4 damages and replace if necessary

PC18. check the tension of v-belt over the 5 2 3 roller pulley

PC19. inspect the cutter bar, knife, star wheels, pressure springs and lugs for damage 5 2 3 and take corrective actions PC20. lubricate all moving parts 5 1 4

PC21. repaint surface where paint has 5 2 3 worn off 100 30 70 2. AGR/N1116 Carry out 100 operation of thresher PC1. select the right thresher based on the 5 1 4 type, capacity and suitability to crops

PC2. check the direction of wind and install 5 1 4 thresher along the direction of the wind

PC3. ensure the thresher is at level by fixing 5 2 3 pegs around the wheels

PC4. mount the prime mover on the frame 4 1 3 and check alignment

PC5. check belt tension and correct 5 2 3 accordingly as per the operators manual

Operator-Reaper, Thresher and Crop Residue Machinery PC6. carry out adjustments for speed of threshing cylinder, cylinder concave 5 1 4 clearance, speed of blower, air flow, sieve slope and stroke length and speed of crank according to operator’s manual PC7. ensure all nuts and bolts are tightened 4 1 3

PC8. check the level, alignment of thresher 5 2 3 and ensure appropriate belt tension

PC9. check the proper size of sieve and 5 2 3 conclave

PC10. check the direction of rotation of 4 1 3 cylinder

PC11. ensure lubrication of parts as per 4 1 3 operator’s manual

PC12. check the level of oil/water in IC 5 2 3 engine or tractor PC13. start the prime mover and thresher 5 2 3

PC14. measure the speed of the thresher using a prime mover and ensure the desired 5 2 3 speed is maintained

PC15. feed crop slowly and uniformly and 5 2 3 collect the clean grain after 1 hour of operation

PC16. measure threshing efficiency and change cylinder speed to ensure maximum 5 2 3 efficiency

PC17. ensure safety precautions as per 5 1 4 operator’s manual during operation of thresher

PC18. carry out minor repair and 5 1 4 maintenance as per operator’s manual

PC19. clear the thresher of grain, chaff, etc. 5 1 4 during idle period

PC20. carry out regular lubrication of moving 5 1 4 parts to reduce wear and tear PC21. inspect and tighten all nuts and bolts 4 1 3

100 30 70 3. AGR/N1117 Carry out 100 field residue management PC1. select appropriate farm machinery to facilitate the application of residues such as 5 2 3 straw chopper, straw baler, chaff cutter, etc. .

PC2. check for proper functioning of the 4 1 3 machinery by performing pre start up checks PC3. take rectifying action if necessary 4 1 3 PC4. stack the straw neatly for pickup 4 1 3

PC5. choose the mode of transport for transportation of straw to the storage facility 5 2 3 such as tractors, trailers

Operator-Reaper, Thresher and Crop Residue Machinery PC6. pick up straw/hay from the ground 4 1 3 using baler teeth

PC7. ensure that once the baler chamber is full with hay/straw, the hay wraps and forms a 5 1 4 cylinder

PC8. ensure that protective coating has been attached to the cylindrical bundle of hay 5 2 3 so that it does not come apart during movement

PC9. transport the bale of straw/hay to the 4 1 3 designated area of storage

PC10. check functioning of chain conveyor, pressing rollers, and upper and lower feed 4 1 3 rollers

PC11. identify and familiarize self with different sub-assemblies and components, 5 2 3 materials, construction of straw choppers

PC12. operate the machine as per standard 5 1 4 operating instructions given

PC13. identify faults and take corrective 4 1 3 action wherever necessary

PC14. select the appropriate hard or power 5 2 3 operated chaff cutters

PC15. check for adjustments of chaff cutter such as feeding chute and mechanism, 5 1 4 feeding rollers, cutting gap, length of cut, etc.

PC16. identify common faults and take 4 1 3 rectifying action PC17. record the quality of output 4 1 3

PC18. identify the need for minor repair and maintenance like replacement of gears, 5 1 4 sharpening of cutting blade, etc.

PC19. develop inventory of amount of 5 2 3 residues generated in different crops

PC20. identify the major uses of crop 4 1 3 residues

PC21. quantify the permissible amount of residues of different crops which can be 5 2 3 incorporated/retained depending on cropping systems, soil, and climate without creating operational problems for the next crop

PC22. assess the quality of crop residues 5 2 3 and their suitability for various purposes

100 30 70 4. AGR/N9903 Maintain 100 health and safety at the PC1. undertake basic safety checks before 6 2 4 workplace operation of all machinery and vehicles and report all potential hazards to the supervisor

Operator-Reaper, Thresher and Crop Residue Machinery PC2. identify work for which protective clothing or equipment is required and perform 7 2 5 those duties in accordance with workplace policy

PC3. read and understand the hazards of 7 2 5 use and contamination mentioned on the labels of pesticides/fumigants, etc.

PC4. assess risks prior to performing 7 2 5 manual handling jobs, and work according to currently recommended safe practices

PC5. use equipment and materials safely 7 2 5 and correctly and return the same to designated storage when not in use

PC6. dispose off waste safely and correctly 6 2 4 in a designated area

PC7. recognize risks to bystanders and take 7 2 5 action to reduce risk associated with jobs in the workplace

PC8. perform work in a manner which minimizes environmental damage all 7 2 5 procedures and ensure work instructions for controlling risks are followed closely

PC9. report any accidents, incidents or problems without delay to an appropriate 7 2 5 person and take necessary immediate action to reduce further danger

PC10. follow procedures for dealing with accidents, fires and emergencies, including 7 2 5 communicating location and directions for emergency evacuation

PC11. follow emergency procedures to 6 2 4 company standard / workplace requirements

PC12. use emergency equipment in accordance with manufacturers' specifications 7 2 5 and workplace requirements

PC13. provide treatment appropriate to the patient's injuries in accordance with 7 2 5 recognized first aid techniques

PC14. recover (if practical), clean, inspect/test, refurbish, replace and store the 6 2 4 first aid equipment as appropriate

PC15. report details of first aid administered 6 2 4 in accordance with workplace procedures. 100 30 70 GRAND TOTAL 400 400 120 280

Operator-Reaper, Thresher and Crop Residue Machinery OPTIONS Option 1: AGR/N1118 Carry out operation of crop residue management machinery Marks Allocation Total Marks: 100

Total Out Of Theory Skills Marks Practical Assessment outcomes Assessment criteria for outcomes 1. AGR/N1118 Carry out 100 operation of crop residue PC1. select the type of cleaner/ grader 6 1 5 management machinery like air screen cleaners, rotary cleaners, etc. based on suitability to farm produce

PC2. check for adjustment and alignment of feed rate, sieve slope, air flow rate, frequency of oscillations 6 2 4 · Carry out operation of straw chopper · Carry out operation of straw baler

PC3. record the quality of output of the 6 2 4 grain

PC4. identify common faults and take 5 2 3 rectifying action

PC5. identify the need for minor repair 6 2 4 and carry out regular maintenance of cleaning and grading machinery

PC6. select the appropriate drying method like convection/conduction drying, 6 1 5 vacuum drying and the appropriate dryer like batch dryer, LSU dryer, etc.

PC7. check for adjustments of air 6 1 5 temperature, grain flow rate in accordance with operator manual

PC8. record the quality of output after 6 2 4 drying

PC9. identify common faults and take 6 2 4 rectifying action of drying machinery

PC10. identify the need for minor repair 6 2 4 and carry out regular maintenance of drying machinery

PC11. select the appropriate type of mill 6 2 4 like based on the type of crop for example dal mill, rice mill, four mills, etc.

PC12. check for adjustments of spacing 6 2 4 between plates and rolls, rpm, screen size, etc.

PC13. select the appropriate oil expelling machinery like oil ghani, screw expeller, 6 1 5 hydraulic press, etc. based on the type of crop

Operator-Reaper, Thresher and Crop Residue Machinery PC14. check for adjustments of feed rate, 6 2 4 operating pressure, moisture content and temperature of oil seeds

PC15. record the quality of output after 6 2 4 milling and oil expelling

PC16. identify common faults and take 5 2 3 rectifying action of milling and oil expelling machinery

PC17. identify the need for minor repair 6 2 4 and carry out regular maintenance GRAND TOTAL 100 100 30 70

Operator-Reaper, Thresher and Crop Residue Machinery